JP3087405B2 - Manufacturing method of decorative sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative sheet for use on surfaces of furniture and objects, surfaces of interior materials of buildings, and the like.

[0002]

2. Description of the Related Art Conventionally, there are various types of decorative sheets used for the above-mentioned industrial applications. this house,
The following types of products are generally used as products having irregularities on the surface and having a continuous shape, but each has advantages and disadvantages.

[0003] Printed and embossed vinyl chloride sheets are excellent in design, but are inferior in heat resistance and solvent resistance due to the thermoplastic resin, so that the surface of the desk, such as a horizontal surface, is poor. It could not be used for parts where durability was important.

Further, a decorative sheet obtained by superposing impregnated paper obtained by impregnating a melamine resin, a diallyl phthalate resin or the like on titanium paper with a backing material, sandwiching it with a long metal belt, and continuously applying heat and pressure to form a decorative sheet. is there. According to this method, a product with high durability is obtained, but the production equipment cost is high, the productivity is low, and there is a drawback that the cost is high because the embossed sheet is disposable to form the emboss. .

Further, as disclosed in Japanese Patent Application Laid-Open No. 57-21965, after applying an electron beam-curable resin to the surface of a continuous sheet-shaped material, a substrate is laminated, and the resin is irradiated with an electron beam to dispense the resin. Although a method of manufacturing an embossed sheet by curing is disclosed, this method also lacks practicality in that an expensive embossed sheet is used. As another method of forming unevenness using an electron beam, there is Japanese Patent Application Laid-Open No. 4994645/1979, but this method is similar in that an endless belt having an uneven pattern is used.

On the other hand, as disclosed in Japanese Patent Application Laid-Open No. 2-131175, a concave portion of a roll intaglio is filled with an ionizing radiation-curable resin, and a film substrate is brought into contact with the resin and cured by irradiating with ionizing radiation. Discloses a method for producing a film having an uneven surface. This specification also describes an electron beam curing method as ionizing radiation curing.
However, from the viewpoint of Examples and the like, it can be considered as a method of producing a film having a concave-convex surface by irradiating ultraviolet rays substantially using a transparent film as a base material. That is, this method does not describe the idea of using paper as a base material or of penetrating a resin between papers.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and the problems are as follows.
It is an object of the present invention to provide a method for efficiently producing a decorative sheet having both surface performance such as surface hardness, heat resistance and abrasion resistance and design.

[0008]

According to the present invention, there is provided a titanium sheet for decorative board, kraft paper, tissue paper and the like.
An electron beam-curable resin composition is applied to the surface of a paper having good resin absorbability selected from high quality paper, and a part of the electron beam-curable resin composition is allowed to penetrate between the papers and reach near the back surface, After leaving a part on the surface, the uncured surface is pressed against the surface of the shaping roll having good electron beam reflection efficiency with unevenness by irradiating an electron beam from the back surface of the paper to the electron beam. An object of the present invention is to provide a method for producing a decorative sheet, characterized in that a curable resin composition is cured and then peeled off from a forming roll. Further, at that time, the electron beam-curable resin composition is mainly composed of an electron beam-curable resin, a reactive monomer, a pigment, a filler, and a small amount of additives, or a pattern is previously formed on the surface of paper, The electron beam-curable resin composition is mainly an electron beam-curable resin, a reactive monomer,
It may be characterized by comprising a transparent filler and a small amount of additives.

Hereinafter, the present invention will be described in detail with reference to the drawings. 1 and 2 show examples of the decorative sheet of the present invention. The papers 1 and 4 used here need to have permeability to a resin described later, and titanium paper for decorative board, kraft paper, tissue paper, high quality paper, or the like can be used. The paper may be colored opaque, white opaque, or transparent paper.

On the surface of the paper, a concealed solid layer, a pattern 2
May be printed. In the most preferred embodiment, a pattern is printed on opaque titanium paper for decorative board having a basis weight of about 60 to 200 g / m ² .

FIG. 3 shows an example of the manufacturing method. The electron beam-curable resin composition 7 is applied to the surface of the support 6 of the decorative sheet obtained as described above. The coating method is optional, but is generally performed using a roll coater, a reverse roll coater, a gravure coater, a knife coater, or the like. FIG.
Shows the case of the gravure coater 8.

The transparent electron beam-curable resin composition 3 obtained by printing the pattern shown in FIG. 1 mainly comprises an electron beam-curable resin, a reactive monomer, and additives. In the case of FIG. 2 in which a plain decorative paper is manufactured, the electron beam-curable resin composition 5 may have a concealing property by further adding a pigment and a filler to the above substance.

The electron beam-curable resin used here does not need to be special, and various commercially available resins can be used. However, in consideration of various physical properties, light resistance, price, and the like as building materials, oligomers of acrylates and methacrylates such as urethane acrylate, polyester acrylate, epoxy acrylate, and silicon acrylate, and mixtures thereof are desirable.

[0014] When various acrylic acid (methacrylic acid) ester monomers are added to these resins, the viscosity is reduced and the coating suitability and impregnation are improved. Also various surfactants,
The addition of a small amount of a release agent or a wax is effective for improving the releasability from the cooling roll after curing and for giving the product slipperiness. Further, a transparent filler such as silica may be added to improve abrasion resistance.

Next, the timing at which the uncured electron beam-curable resin composition 9 thus applied penetrates to the vicinity of the back surface of the paper of the support and partially remains on the surface is measured. The pressure is applied to the surface of the shaping roll 11. The shaping role is
It is preferable to apply chrome plating to the surface of a metal roll provided with an uneven pattern having a height of about 100 μm or less on the surface in order to improve the releasability of the resin. In order to absorb some heat generated by the curing of the resin, a cooling mechanism may be provided inside. If the height of the irregularities is 100 μm or more, a large amount of resin is required, which is uneconomical, and the thickness of the resin increases, so that the resulting product lacks flexibility. According to the present method, the reproducibility of the emboss shape is extremely good, so that the height of the emboss is not so necessary.

The material of the shaping roll is preferably a material which efficiently reflects the electron beam. This increases the dose in the vicinity of the roll surface, so that complete curability can be obtained even with a small dose. As a specific material, chrome-plated ordinary steel or stainless steel is good including cost, but this method does not apply much heat to the embossing roll. Chromium plating is also used favorably.

If a rubber roll 10 wound with rubber having good releasability, such as silicon rubber or fluorine rubber, is used for the pressure bonding, the surface of the rubber roll does not need to be contaminated even if the resin goes through.

While the uncured resin composition surface 9 is pressed against the shaping roll 11, the resin is cured by irradiating an electron beam from the back surface of the support with an electron beam irradiation device 12. As the electron beam, an acceleration voltage of 200 to 300 KeV (kilo electron volt) and an irradiation dose of 2 to 5 Mrad (mega rad) are suitable. These treatments are desirably performed in a nitrogen atmosphere in order to prevent the curing of the resin from being inhibited by oxygen.

Finally, after the curing is completed, the decorative sheet 14 in which the paper and the resin are integrated is peeled off from the forming roll and wound up to obtain a desired decorative sheet.

[0020]

As described above, in the decorative sheet 14 thus obtained, the fine surface shape of the imprinting roll is accurately copied on the surface, and the surface is covered with a high hardness electron beam curable resin. In addition, since the resin penetrates into the inside of the paper layer and is hardened, the strength between paper sheets is high, and the product has extremely high commercial value.

[0021]

【Example】

<Example 1> basis weight printed wood grain pattern to the ocher titanium paper of 100 g / m ^2, and 100 g / m ² coated by a roll coater electron beam-curable resins based on the following formulation on the surface. Approximately 4 seconds after the application, the coated surface is pressed against the surface of a shaping roll engraved with a wood grain tube pattern, and irradiated with an electron beam of 250 KeV and 3 Mrad to cure the electron beam-curable resin. And was wound up. This decorative sheet was adhered to the surface of the particle board using an epoxy adhesive to prepare a decorative plate. The decorative board obtained in this way reproduces the shape and texture of the vascular embossment on the surface extremely faithfully, and while feeling the texture of the PVC decorative sheet, the surface hardness, heat resistance, abrasion resistance, etc. It had excellent performance and could be used for horizontal surfaces.

<Formulation 1> 100 parts of polyester acrylate resin ("Aronix M8030" manufactured by Toa Gosei Co., Ltd.) 5 parts of filler (silica) Release agent (5 parts of "Evecryl CV515" manufactured by Daicel UCB Co., Ltd.)

Example 2 An electron beam-curable resin composition based on the following composition was applied to a surface of a thin paper having a basis weight of 30 g / m ² by a roll coater at 50 g / m ² . After about 4 seconds, the coated surface is pressed against the surface of an embossed roll of an abstract pattern having irregularities of about 20 μm, irradiated with an electron beam of 250 KeV and 3 Mrad, cured, and then peeled off from the forming roll and wound up Was. This decorative sheet was adhered to the surface of the particle board using an epoxy adhesive to prepare a decorative plate. The plain embossed veneer thus obtained had a fine embossed shape faithfully reproduced on the surface, had a high surface hardness, and was excellent in abrasion.

<Formulation 2> Urethane acrylate resin 100 parts (“Evecryl 1290” manufactured by Daicel UCB) Monomer (HDDA) 40 parts Pigment (carbon black) 5 parts Filler (silica) 5 parts Release agent (Daicel) UCB Co., Ltd. "Evecryl CV515" 5 copies

Example 3 Colored printing and a grain-grained abstract pattern were printed on thin paper having a basis weight of 30 g / m ² , and 25 g of an electron beam-curable resin composition based on the following composition was printed on the surface thereof using a roll coater. / m ^{2 was} applied. Approximately 2 seconds after application, apply surface
It was pressed against the surface of an embossed roll having an abstract pattern having an irregular surface of about 20 μm, cured by irradiation with an electron beam of 200 KeV and 3 Mrad, and then peeled off from the forming roll and wound up. This decorative sheet was adhered to the surface of a particle board using a urea vinyl acetate adhesive to prepare a decorative plate. The embossed decorative board thus obtained had a fine grain embossed shape faithfully reproduced on the grain print pattern and the surface, had a three-dimensional effect, and was very excellent in design.

<Formulation 3> Acrylic resin 100 parts (“Evecryl 1016” manufactured by Daicel UCB) Monomer (HDDA) 20 parts Filler (silica) 5 parts Release agent (Daicel UCB Co., Ltd. “Evecryl”) CV515 ") 5 copies

[0027]

As described above, according to the present invention, since the liquid resin is pressed against the forming roll in an uncured state and cured as it is, the reproducibility of the embossed shape is extremely good.
Further, since the surface of the decorative sheet is in close contact with the shaping roll, it is not hindered by oxygen at the time of curing. Therefore, even if the oxygen concentration is high, problems such as poor curing do not occur. For this reason, there is an advantage that the amount of nitrogen gas for air purging can be reduced. Further, since the liquid resin penetrates into the paper and hardens, thereby strengthening the paper interval, it is possible to obtain a decorative sheet having excellent performance not only on the surface but also over the entire thickness. Furthermore, since the surface of the forming roll according to the present invention reflects an electron beam, the irradiation dose can be reduced, and the irradiation device can be inexpensive.
Further, since it is not necessary to heat the shaping roll, an inexpensive resin roll can be used. In addition, since the color tone of the base material and the resin is not selected, the combination can be freely selected.

[0028]

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing a cross section of a decorative sheet according to an embodiment of the present invention using a paper on which a pattern is printed and a transparent resin.

FIG. 2 is an explanatory diagram showing a cross section of an embodiment using a plain paper and a resin containing a pigment in a decorative sheet according to the present invention.

FIG. 3 is an explanatory view showing a method for producing a decorative sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Paper 2 ... Printed pattern 3 ... Transparent resin layer cured by electron beam 4 ... Paper 5 ... Pigmented resin layer cured by electron beam 6 ... Support for decorative sheet 7 ... Electron beam curable resin composition Reference Signs List 8 gravure roll 9 uncured resin composition layer 10 pressure bonding roll 11 shaping roll 12 electron beam irradiation device 13 peeling roll 14 decorative sheet

Continuation of front page (56) References JP-A-57-21966 (JP, A) JP-A-58-25926 (JP, A) JP-A-4-219168 (JP, A) (58) Fields studied (Int .Cl. ⁷ , DB name) B32B 1/00-35/00 B05D 1/00-7/26

Claims (3)

(57) [Claims] 1. Titanium paper for decorative board, kraft paper, tissue paper and
An electron beam-curable resin composition is applied to the surface of a paper having good resin absorbency selected from high quality paper, and a part of the electron beam-curable resin composition is allowed to penetrate between the papers and reach near the back surface. After leaving a part on the surface, the uncured surface is pressed against the surface of a shaping roll having good electron beam reflection efficiency with unevenness by irradiating an electron beam from the back surface of the paper with the electron beam. A method for producing a decorative sheet, comprising curing a line-curable resin composition and then peeling it off from a forming roll. 2. The decorative sheet according to claim 1, wherein the electron beam-curable resin composition mainly comprises an electron beam-curable resin, a reactive monomer, a pigment, a filler, and a small amount of additives. Manufacturing method. 3. A pattern is formed on the surface of paper in advance, and the electron beam-curable resin composition mainly comprises an electron beam-curable resin, a reactive monomer, a transparent filler and a small amount of additives. The method for producing a decorative sheet according to claim 1.